Honda CRF450R 2009 Owner's Manual & Competition Handbook page 67

Clutch Disc/Plate Inspection
Replace the clutch discs (1) if they show signs of
scoring or discoloration.
Measure the thickness of each clutch disc.
Service Limit: 0.112 in (2.85 mm)
Replace the clutch discs and clutch plates as a set.
(1)
(1) clutch disc
Check the clutch plates (2) for excessive warpage
or discoloration.
Check the plate warpage on a surface plate using
a feeler gauge.
Service Limit: 0.006 in (0.15 mm)
Replace the clutch discs and plates as a set.
(2) clutch plate
If you feel the clutch slippage when replacing the
clutch discs and plates, replace the clutch springs.
Clutch Disc/Plate Installation
1. Coat the clutch discs with engine oil.
2. Install the eight clutch discs (1) and seven
clutch plates (2) alternately, starting with a disc.
(1)
(1) eight clutch discs
(2) seven clutch plates
(2)
3. Insert the clutch lifter rod (3) into the
mainshaft.
4. Apply engine oil to the needle bearing (4) and
washer (5) and install them onto the clutch
lifter (6).
5. Install the clutch lifter onto the rod.
(6)
(3) clutch lifter rod
(4) needle bearing
(2)
6. Install the clutch pressure plate (7).
7. Install the four clutch springs and bolts (8).
8. Tighten the bolts in a crisscross pattern in two
or three steps to the specified torque:
9 lbf·ft (12 N·m, 1.2 kgf·m)
(8)
(7) clutch pressure plate
(8) clutch springs and bolts
Clutch System
(3) (5) (4)
(5) washer
(6) clutch lifter
(7)
(cont'd)
61
Servicing Your Honda